Method and system with mesh data conversion for stamping dies

Abstract

Systems and methods are provided for developing and producing a die using mesh data. A mesh data file representing a surface of the die is created. The mesh data file is configured in an original format that is one of a point-facet format or a node-element format. The mesh data file is translated into a translated format that is another of the point-facet format or the node-element format. Prior to building, the die, as represented by the mesh data file, is evaluated virtually.

What is claimed is: 
     
       1. A method of producing a die, comprising:
 creating, by at least one computer apparatus, a mesh data file representing a surface of the die, wherein the mesh data file is configured in an original format that is one of a point-facet format or a node-element format, where the point-facet format represents the surface by a number of facets, each facet of the number of facets defined by points and is compatible with a first analysis tool, and where the node-element format represents the surface by a number of elements defined by nodes and is compatible with a second analysis tool; 
 translating, by the at least one computer apparatus, the mesh data file into a translated format that is another of the point-facet format or the node-element format, including processing every facet/element in the mesh data file to convert the mesh data file in the original format into the mesh data file in the translated format, including determining whether all facets/elements in the translated format each have a normal vector equal to an original normal vector for a corresponding facet/element in the original format; 
 wherein the translating includes:
 selecting a first point/node of a selected facet/element of the number of facets/elements; 
 selecting a second point/node of the selected facet/element; 
 selecting a third/point node of the selected facet/element 
 calculating a calculated normal vector for the second point/node by a cross product of a first vector from the second point/node to the first point/node and a second vector from the second point/node to the third point/node; 
 comparing the calculated normal vector to the original normal vector for the selected facet/element of the mesh data file in the original format 
 determining whether the first calculated normal vector value at the second point/node equals the original normal vector; 
 saving, when the calculated normal vector is equal to the original normal vector, the selected facet element in the translated node-element/point-facet format with the selected first, second and third points/nodes in their original orientation; 
 swapping, when the calculated normal vector is not equal to the original normal vector, the first point/node with the second point/node to change the orientation of the first and second point/nodes to reflect the original normal vector; 
 saving, when the calculated normal vector is not equal to the original normal vector and with the swapped points/nodes, the facet/element in the translated node-element/point-facet format; 
 wherein the translating is performed for all facets/elements in the mesh data file to obtain the mesh data file in the translated node-element/point-facet format; 
 
 evaluating, by the at least one computer apparatus, the die as represented by the mesh data file in the translated format, prior to building the die to create a corrected mesh data file; and 
 building, by at least one die machining apparatus and using the corrected mesh data file, the die. 
 
     
     
       2. The method of  claim 1 , comprising determining whether all facets/elements in the mesh data file have been processed; continuing the translation when all facets in the data file have not been processed, and cleaning, after all facets/elements in the mesh data file have been processed, the mesh data file. 
     
     
       3. The method of  claim 1 , comprising cleaning, after the translating, the mesh data file by removing certain of the facet/element according to predetermined criteria. 
     
     
       4. The method of  claim 3 , wherein the predetermined criteria comprise those of the facet/element that fall below a threshold size. 
     
     
       5. The method of  claim 1 , comprising outputting the mesh data file, after evaluating the die, for building the die. 
     
     
       6. The method of  claim 1 , wherein the evaluating comprises:
 simulating operation of the die, by the at least one computer apparatus running a first software application as the first analysis tool with the mesh data file in point-facet format; and 
 evaluating a surface of the die, by the at least one computer apparatus running a second software application as the second analysis tool with the mesh data file in node-element format. 
 
     
     
       7. The method of  claim 1 , wherein the evaluating comprises determining, virtually by the at least one computer apparatus, whether operation of the die as represented by the mesh data file results in malformation of a simulated blank material; correcting the mesh data file by modifying a surface of the die; and building, by at least one die machining apparatus, the die using the corrected mesh data file. 
     
     
       8. A system for producing a die, comprising:
 at least one computer apparatus configured to: 
 create a mesh data file representing a surface of a product wherein the mesh data file is configured in an original format that is one of a point-facet format or a node-element format, where the point-facet format represents the surface by a number of facets, each facet of the number of facets defined by points and is compatible with a first analysis tool, and where the node-element format represents the surface by a number of elements defined by nodes and is compatible with a second analysis tool; 
 translate the mesh data file into a translated format that is another of the point-facet format or the node-element format, including processing every facet/element in the mesh data file to convert the mesh data file in the original format into the mesh data file in the translated format, including determining whether all facets/elements in the translated format each have a normal vector equal to an original normal vector for a corresponding facet/element in the original format, including to:
 select a first point/node of a selected facet/element of the number of facets/elements; 
 select a second point/node of the selected facet/element; 
 select a third/point node of the selected facet/element 
 calculate a calculated normal vector for the second point/node by a cross product of a first vector from the second point/node to the first point/node and a second vector from the second point/node to the third point/node; 
 compare the calculated normal vector to the original normal vector for the selected facet/element of the mesh data file in the original format; 
 determine whether the first calculated normal vector value at the second point/node equals the original normal vector; 
 save, when the calculated normal vector is equal to the original normal vector, the selected facet element in the translated node-element/point-facet format with the selected first, second and third points/nodes in their original orientation; 
 swap, when the calculated normal vector is not equal to the original normal vector, the first point/node with the second point/node to change the orientation of the first and second point/nodes to reflect the original normal vector; and 
 save, when the calculated normal vector is not equal to the original normal vector and with the swapped points/nodes, the facet/element in the translated node-element/point-facet format, 
 wherein the translating is performed for all facets/elements in the mesh data file to obtain the mesh data file in the translated node-element/point-facet format; 
 
 evaluate the product as represented by the mesh data file in the translated format, prior to building the product to create a corrected mesh data file; and 
 a die machining apparatus configured to build the die using the corrected mesh data file. 
 
     
     
       9. The system of  claim 8 , wherein the at least one computer apparatus is configured to: determine whether all facets/elements in the mesh data file have been processed; continue the translation when all facets in the data file have not been processed, and clean, after all facets/elements in the mesh data file have been processed, the mesh data file. 
     
     
       10. The system of  claim 8 , wherein the at least one computer apparatus is configured to clean the mesh data file by removing certain of the facet/element according to predetermined criteria. 
     
     
       11. The system of  claim 8 , wherein the at least one computer apparatus is configured to:
 determine whether the mesh data file includes quad-elements; 
 convert, prior to the translate, each quad-element having four nodes found in the mesh data file into two tri-elements each having three nodes; and 
 conduct the translate on all elements in the mesh data file including the converted tri-elements. 
 
     
     
       12. The system of  claim 10 , wherein the at least one computer apparatus is configured to merge points/nodes that are within a threshold distance of each other. 
     
     
       13. The system of  claim 8 , wherein the product comprises a die for stamping, and the at least one computer apparatus is configured to:
 simulate operation of the die while running a first software application as the first analysis tool with the mesh data file in point-facet format; and 
 evaluate a surface of the die while running a second software application as the second analysis tool with the mesh data file in node-element format. 
 
     
     
       14. A method of producing a die for stamping a blank into part, the method comprising:
 creating, by at least one computer apparatus, a mesh data file representing a surface of the die, wherein the mesh data file is configured in an original format that is one of a point-facet format or a node-element format, where the point-facet format represents the surface by a number of facets, each of the number of facets defined by at least three points and is compatible with a first analysis tool, and where the node-element format represents the surface by a number of nodes defining elements and is compatible with a second analysis tool, so that the mesh data file in the original format is created using a selected meshing tool that is part of one of the first analysis tool and the second analysis tool; 
 translating, by the at least one computer apparatus, the mesh data file into a translated format that is another of the point-facet format or the node-element format, wherein the translating includes at least one of converting the mesh data file from the point-facet format to the node-element format and/or converting the mesh data file from the node-element format to the point-facet format, so that the mesh data file in the translated format is compatible with a selected evaluation tool that is another of the first analysis tool and the second analysis tool, and is not the selected meshing tool, wherein the translating includes processing every facet/element in the mesh data file to convert the mesh data file in the original format into the mesh data file in the translated format, including determining whether all facets/elements in the translated format each have a normal vector equal to an original normal vector for corresponding facets/elements in the original format; 
 wherein the translating includes:
 selecting a first point/node of a selected facet/element of the number of facets/elements; 
 selecting a second point/node of the selected facet/element; 
 selecting a third/point node of the selected facet/element 
 calculating a calculated normal vector for the second point/node by a cross product of a first vector from the second point/node to the first point/node and a second vector from the second point/node to the third point/node; 
 comparing the calculated normal vector to the original normal vector for the selected facet/element of the mesh data file in the original format; 
 determining whether the first calculated normal vector value at the second point/node equals the original normal vector; 
 saving, when the calculated normal vector is equal to the original normal vector, the selected facet element in the translated node-element/point-facet format with the selected first, second and third points/nodes in their original orientation; 
 swapping, when the calculated normal vector is not equal to the original normal vector, the first point/node with the second point/node to change the orientation of the first and second point/nodes to reflect the original normal vector; 
 saving, when the calculated normal vector is not equal to the original normal vector and with the swapped points/nodes, the facet/element in the translated node-element/point-facet format; 
 wherein the translating is performed for all facets/elements in the mesh data file to obtain the mesh data file in the translated node-element/point-facet format; 
 
 evaluating, by the at least one computer apparatus using the second analysis tool, the die as represented by the mesh data file in the translated format, prior to building the die; and 
 building, by at least one die machining apparatus and after the evaluating using the second analysis tool, the die using the mesh data file.